FAILURE MODE AND EFFECT ANALYSIS

UNIT BISNIS OPERASI DAN PEMELIHARAAN PLTU BANTEN 1 SURALAYA

FMEA Form 1 No. : FMEA-111-R00/ELC/BSR/2014

System : CONDENSATE SYSTEM KKS : CS10LCA10BR001 Finishing Date : 21 Maret 2014

Equipment : MAIN CONDENSATE PIPING Alias KKS : 10LCA10BR000 Workshop Date : 18 Maret 2014
Component : 1. MOV SUCTION CEP A MPI : 227,684 Revision : 00
2. MOV SUCTION CEP B

Failure Effect on Recommended Action

Alias KKS of Comp. /
No Item Identification Function Failure Mode Failure Cause OCC CRT SEV Failure Detection Method DET RPN
Amount of Comp. Component or Next Higher Assembly
System Description Frequency PIC
Functional Assembly (Equipment)

- Cek tahanan isolasi kabel

10LCA10AA001A & MOV tidak mendapatkan Sistem air kondensat berikut rangkaian MOV
1 MOV POWER SUPPLY Suplai power ke MOV MCB-TRIPPED SHORT-CIRCUIT 1 N MOV tidak dapat digerakkan 4 Corrective Action 5 20 AR SPS HL
10LCA10AA002 / 1 suplai power terganggu - Cek kondisi MCB
- Repair/replace

- Cek wiring/koneksi
- Cek kondisi kabel & test
MOV tidak mendapatkan Sistem air kondensat
UNBALANCE PHASE-LOSS 1 N MOV tidak dapat digerakkan 4 Corrective Action 5 20 continuity AR SPS HL
suplai power terganggu
- Cek incoming & feeder
- Repair

- Cek wiring/koneksi
POWER-MODULE- MOV tidak mendapatkan Sistem air kondensat
NO-POWER 2 N MOV tidak dapat digerakkan 4 Corrective Action 5 40 - Cek kondisi card module AR SPS HL
FAILURE suplai power terganggu
- Repair/replace

Mengubah energi listrik

- Cek setting temperature
10LCA10AA001A & menjadi energi mekanik, Sistem air kondensat
2 MOV MOTOR OVERHEAT OVERCURRENT 1 N Motor rusak MOV tidak dapat digerakkan 3 Corrective Action 5 15 - Cek load motor AR SPS HL
10LCA10AA002 / 1 sebagai penggerak valve terganggu
- Repair
secara electrical

- Cek tahanan isolasi motor

Sistem air kondensat
OVERHEAT SHORT-CIRCUIT 1 N Motor rusak MOV tidak dapat digerakkan 3 Corrective Action 5 15 - Cek kabel & wiring AR SPS HL
terganggu
- Repair/replace
- Cek tahanan isolasi motor
INSULATION- Sistem air kondensat
OVERHEAT 1 N Motor rusak MOV tidak dapat digerakkan 3 Corrective Action 5 15 - Cek kabel & wiring AR SPS HL
DEGRADATION terganggu
- Repair/replace
- Cek kondisi sensor
Motor tidak dapat Sistem air kondensat
OVERHEAT SENSOR-FAILURE 1 N MOV tidak dapat digerakkan 3 Corrective Action 5 15 - Kalibrasi sensor AR SPS HL
berfungsi terganggu
- Repair/replace
10LCA10AA001A & Pentransmisi energi mekanis GEAR-TOOTH- Motor tidak dapat men- MOV tidak beroperasi dengan Sistem air kondensat
3 MOV GEARBOX JAMMED 2 N 4 Periodic Inspection 4 32 Pelumasan saat OH 52W SPS HL
10LCA10AA002 / 1 yang dihasilkan oleh motor DAMAGED drive valve normal terganggu
Motor tidak dapat men- MOV tidak beroperasi dengan Sistem air kondensat
SLUGGISH CORROSION 2 N 4 Periodic Inspection 4 32 Pelumasan saat OH 52W SPS HL
drive valve normal terganggu

10LCA10AA001A & Backup power positioner dan Posisi opening valve tidak MOV tidak beroperasi dengan Sistem air kondensat
4 MOV BATTERY BATTERY-LOW WORN 3 N 2 Periodic Inspection 4 24 Penggantian battery saat OH 52W SPS HL
10LCA10AA002 / 1 LCD saat main power OFF terbaca; MOV fault alarm normal terganggu

Posisi opening valve tidak MOV tidak beroperasi dengan Sistem air kondensat
BATTERY-LOW WORN 3 N 2 Corrective Action 5 30 Ganti battery AR SPS HL
terbaca; MOV fault alarm normal terganggu

10LCA10AA001A & Rangkaian pengendali dan Kondisi/status MOV tidak MOV tidak beroperasi dengan Sistem air kondensat
5 MOV CONTROL CIRCUIT LCD-BLANK LCD-BROKEN 1 N 2 Corrective Action 5 10 Ganti module LCD AR SPS HL
10LCA10AA002 / 1 pengkondisi sinyal terpantau normal terganggu
Kondisi/status MOV tidak MOV tidak beroperasi dengan Sistem air kondensat
LCD-BLANK BATTERY-LOW 1 N 2 Corrective Action 5 10 Ganti battery AR SPS HL
terpantau normal terganggu
INNER-COMMUNICATION- NO-SIGNAL-VALVE- MOV tidak beroperasi dengan Sistem air kondensat
1 N MOV fault alarm 4 Corrective Action 5 20 Ganti/repair module AR SPS HL
ERROR POSITION normal terganggu
INNER-COMMUNICATION- MOV tidak beroperasi dengan Sistem air kondensat
CONNECTION-LOOSE 1 N MOV fault alarm 4 Corrective Action 5 20 Cek connection AR SPS HL
ERROR normal terganggu
LOCAL-PCB-AND-MAIN-
MOV tidak beroperasi dengan Sistem air kondensat
LOCAL-MODULE-ERROR PCB-CONNECTION- 1 N MOV fault alarm 4 Corrective Action 5 20 Ganti/repair module AR SPS HL
normal terganggu
FAILURE
MOV tidak beroperasi dengan Sistem air kondensat
LOCAL-MODULE-ERROR CONNECTION-LOOSE 1 N MOV fault alarm 4 Corrective Action 5 20 Cek connection AR SPS HL
normal terganggu
MOV tidak beroperasi dengan Sistem air kondensat
ESD CONTROL-FAILURE 2 N MOV fault alarm 4 Corrective Action 5 40 Ganti/repair module AR SPS HL
normal terganggu
MOV tidak beroperasi dengan Sistem air kondensat
ESD CONNECTION-LOOSE 1 N MOV fault alarm 4 Corrective Action 5 20 Cek connection AR SPS HL
normal terganggu
MOV tidak beroperasi dengan Sistem air kondensat
SIGNAL-LOST CONTROL-FAILURE 1 N MOV fault alarm 4 Corrective Action 5 20 Ganti/repair module AR SPS HL
normal terganggu
MOV tidak beroperasi dengan Sistem air kondensat
SIGNAL-LOST CONNECTION-LOOSE 1 N MOV fault alarm 4 Corrective Action 5 20 Cek connection AR SPS HL
normal terganggu
 FAILURE MODE AND EFFECT ANALYSIS
UNIT BISNIS OPERASI DAN PEMELIHARAAN PLTU BANTEN 1 SURALAYA
FMEA Form 1 No. : FMEA-111-R00/ELC/BSR/2014

System : CONDENSATE SYSTEM KKS : CS10LCA10BR001 Finishing Date : 21 Maret 2014

Equipment : MAIN CONDENSATE PIPING Alias KKS : 10LCA10BR000 Workshop Date : 18 Maret 2014
Component : 1. MOV SUCTION CEP A MPI : 227,684 Revision : 00
2. MOV SUCTION CEP B

TORQUE-SIGNAL-OUT- MOV tidak beroperasi dengan Sistem air kondensat

TORQUE-MODULE-ERROR 1 N MOV fault alarm 4 Corrective Action 5 20 Ganti/repair module AR SPS HL
OF-RANGE normal terganggu
MOV tidak beroperasi dengan Sistem air kondensat
TORQUE-MODULE-ERROR CONNECTION-LOOSE 1 N MOV fault alarm 4 Corrective Action 5 20 Cek connection AR SPS HL
normal terganggu
CONTROL-MODULE- MOV tidak beroperasi dengan Sistem air kondensat
24V-ERROR 1 N MOV fault alarm 4 Corrective Action 5 20 Ganti/repair module AR SPS HL
FAILURE normal terganggu
MOV tidak beroperasi dengan Sistem air kondensat
24V-ERROR CONNECTION-LOOSE 1 N MOV fault alarm 4 Corrective Action 5 20 Cek connection AR SPS HL
normal terganggu
POSISION-CIRCUIT- MOV tidak beroperasi dengan Sistem air kondensat
PV-MODULE-ERROR 1 N MOV fault alarm 4 Corrective Action 5 20 Ganti/repair module AR SPS HL
FAILURE normal terganggu
MOV tidak beroperasi dengan Sistem air kondensat
PV-MODULE-ERROR CONNECTION-LOOSE 1 N MOV fault alarm 4 Corrective Action 5 20 Cek connection AR SPS HL
normal terganggu
EXTENSION-MODULE-
AND-MAIN-MODULE- MOV tidak beroperasi dengan Sistem air kondensat
EXTENSION-MODULE-ERROR 1 N MOV fault alarm 4 Corrective Action 5 20 Ganti/repair module AR SPS HL
COMMUNICATION- normal terganggu
FAILURE
MOV tidak beroperasi dengan Sistem air kondensat
EXTENSION-MODULE-ERROR CONNECTION-LOOSE 1 N MOV fault alarm 4 Corrective Action 5 20 Cek connection AR SPS HL
normal terganggu
CONTROL-CIRCUIT-
AND-MEMORY- MOV tidak beroperasi dengan Sistem air kondensat
MAIN-MODULE-ERROR 1 N MOV fault alarm 4 Corrective Action 5 20 Ganti/repair module AR SPS HL
COMMUNICATION- normal terganggu
FAILURE
MOV tidak beroperasi dengan Sistem air kondensat
MAIN-MODULE-ERROR CONNECTION-LOOSE 1 N MOV fault alarm 4 Corrective Action 5 20 Cek connection AR SPS HL
normal terganggu

Sebagai sensor pembatas Motor overload; valve

10LCA10AA001A & LIMIT-SWITCH- MOV tidak beroperasi dengan Sistem air kondensat
6 MOV LIMIT SWITCH opening dan closing valve IMPROPER-SETTING 2 N stem bengkok; valve 4 Corrective Action 5 40 Kalibrasi setting limit switch AR SPS HL
10LCA10AA002 / 1 MALFUNCTION normal terganggu
berdasarkan sentuhan mekanis malfunction, leakthrough

Motor overload; valve

LIMIT-SWITCH- MOV tidak beroperasi dengan Sistem air kondensat
SWITCH-BROKEN 1 N stem bengkok; valve 4 Corrective Action 5 20 Ganti limit switch AR SPS HL
MALFUNCTION normal terganggu
malfunction, leakthrough

Motor overload; valve

LIMIT-SWITCH- MOV tidak beroperasi dengan Sistem air kondensat
CONTAMINATION 1 N stem bengkok; valve 4 Corrective Action 5 20 Cleaning/repair AR SPS HL
MALFUNCTION normal terganggu
malfunction, leakthrough

Sebagai sensor pembatas Motor overload; valve

10LCA10AA001A & TORQUE-SWITCH- MOV tidak beroperasi dengan Sistem air kondensat
7 MOV TORQUE SWITCH opening dan closing valve IMPROPER-SETTING 2 N stem bengkok; valve 4 Corrective Action 5 40 Kalibrasi setting torque switch AR SPS HL
10LCA10AA002 / 1 MALFUNCTION normal terganggu
berdasarkan besar torsi malfunction, leakthrough

Motor overload; valve

TORQUE-SWITCH- MOV tidak beroperasi dengan Sistem air kondensat
SWITCH-BROKEN 1 N stem bengkok; valve 4 Corrective Action 5 20 Ganti torque switch AR SPS HL
MALFUNCTION normal terganggu
malfunction, leakthrough

Motor overload; valve

TORQUE-SWITCH- MOV tidak beroperasi dengan Sistem air kondensat
CONTAMINATION 1 N stem bengkok; valve 4 Corrective Action 5 20 Cleaning/repair AR SPS HL
MALFUNCTION normal terganggu
malfunction, leakthrough

10LCA10AA001A & MOV tidak beroperasi dengan Sistem air kondensat

8 MOV VALVE Mengontrol aliran fluida OVERTORQUE CORROSION 2 N MOV fault alarm 4 First Line Maintenance 3 24 Pelumasan jika dibutuhkan AR SPS RNOP
10LCA10AA002 / 1 normal terganggu
MOV tidak beroperasi dengan Sistem air kondensat
OVERTORQUE STEM-BENT 2 N MOV fault alarm 4 Corrective Action 5 40 Repair stem AR SPS HM
normal terganggu
MOV tidak beroperasi dengan Sistem air kondensat
OVERTORQUE SETTING-TOO-LOW 2 N MOV fault alarm 4 Corrective Action 5 40 Re-setting AR SPS HL
normal terganggu
TORQUE-HELIX- MOV tidak beroperasi dengan Sistem air kondensat
OVERTORQUE 1 N MOV fault alarm 4 Corrective Action 5 20 Repair/replace AR SPS HL
ABNORMAL normal terganggu
MOV tidak beroperasi dengan Sistem air kondensat
STALLED CORROSION 2 N MOV fault alarm 4 First Line Maintenance 3 24 Pelumasan jika dibutuhkan AR SPS RNOP
normal terganggu
MOV tidak beroperasi dengan Sistem air kondensat
STALLED GEARBOX-BROKEN 1 N MOV fault alarm 4 Corrective Action 5 20 Repair stem AR SPS HM
normal terganggu
DRIVE-BUSH- MOV tidak beroperasi dengan Sistem air kondensat
STALLED 1 N MOV fault alarm 4 Corrective Action 5 20 Replace AR SPS HL
ABNORMAL normal terganggu
 FAILURE MODE AND EFFECT ANALYSIS
UNIT BISNIS OPERASI DAN PEMELIHARAAN PLTU BANTEN 1 SURALAYA
FMEA Form 1 No. : FMEA-111-R00/ELC/BSR/2014

System : CONDENSATE SYSTEM KKS : CS10LCA10BR001 Finishing Date : 21 Maret 2014

Equipment : MAIN CONDENSATE PIPING Alias KKS : 10LCA10BR000 Workshop Date : 18 Maret 2014
Component : 1. MOV SUCTION CEP A MPI : 227,684 Revision : 00
2. MOV SUCTION CEP B

NOT-FULLY-OPENED-OR- MOV tidak beroperasi dengan Sistem air kondensat

STEM-BENT 2 N Leakthrough 2 Corrective Action 5 20 Repair stem AR SPS HM
CLOSED normal terganggu
NOT-FULLY-OPENED-OR- MOV tidak beroperasi dengan Sistem air kondensat
SETTING-ABNORMAL 2 N Leakthrough 2 Corrective Action 5 20 Re-setting AR SPS HL
CLOSED normal terganggu
MOV tidak beroperasi dengan Sistem air kondensat
LEAKAGE PACKING-WORN 2 N Leakthrough; leakout 2 Corrective Action 5 20 Replace packing AR SPS HL
normal terganggu
MOV tidak beroperasi dengan Sistem air kondensat
LEAKAGE STEM-WORN 1 N Leakthrough; leakout 2 Corrective Action 5 10 Replace stem AR SPS HM
normal terganggu

Name Position Date Sign

No Reference
1 Title : AI/MI Actuator Instructions
Prepared by Lufti Nul Hakim AMA ENG Listrik
Doc. No. :
Manufacture : Shanghai Automation Instrumentation Co.,Ltd
2 Title : Preventive Maintenance Basis Reviewed by Erik Pujianto SPS Reliability
Doc. No. :
Institution : EPRI Hedwig Lunga
Approved by MENJ
S.P.
 UNIT BISNIS OPERASI DAN PEMELIHARAAN PLTU BANTEN 1 SURALAYA

FMEA Form 1 No. : FMEA-0111-R00/MEC/BSR/2014

System : CONDENSATE SYSTEM KKS : CS10LCA10BR001 Finishing Date : 21 MARET 2014

Equipment : MAIN CONDENSATE PIPING Alias KKS : 10LCA10BR000 Workshop Date : 18 MARET 2014
Component :- MPI : 227.684 Revision : 00

No Failure Effect on Recommended Action Keterangan

Alias KKS of Comp. / Amount
Item Identification Function Failure Mode Failure Cause Failure Detection Method
of Comp. Component or Functional Assembly Next Higher Assembly (Equipment) System Description Frequency PIC

Condensate piping condensate water pump for Leaking pipe Corrosion Thin-edge tube Leak/split Shutdown pump 1 Operator round 1 Do operator round, visual check for Every shift SPS OP
preheater and then to feed abnormalitiers in condensate pipe
water storage tank 2 Chemical operator check 2 Chemical water sample monitoring Every shift SPS KLK3
3 Maintenance check 3 Visual check, replace or repair pipe Event base SPS HM
failure
In-proper installation Broken pipe Leak Shutdown pump 1 Operator round 1 Do operator round, visual check for Every shift SPS OP
abnormalitiers in condensate pipe
2 Chemical operator check 2 Chemical water sample monitoring Every shift SPS KLK3
3 Maintenance check 3 Visual check, replace or repair pipe Event base SPS HM
failure

Leaking flange Gasket failure Broken gasket Leak Shutdown pump 1 Operator round 1 Do operator round, visual check for Every shift SPS OP
abnormalitiers in condensate pipe
2 Maintenance check 2 Visual check, replace gasket Event base SPS HM
Loose bolts Leak Shutdown pump 1 Operator round 1 Do operator round, visual check for Every shift SPS OP
abnormalitiers in condensate pipe
2 Maintenance check 2 Visual check, tighten bolts Event base SPS HM

Corroded pipe Chemical reaction Thin-edge tube Leak/split Shutdown pump 1 Operator round 1 Do operator round, visual check for Every shift SPS OP
abnormalitiers in condensate pipe
2 Chemical operator check 2 Chemical water sample monitoring Every shift SPS KLK3
3 Maintenance check 3 Visual check, replace or repair pipe Event base SPS HM
failure
Hygro-mechanical Formed deposite Clogged Shutdown pump 1 Operator round 1 Do operator round, visual check for Every shift SPS OP
(moisture absorption) abnormalitiers in condensate pipe

2 Chemical operator check 2 Chemical water sample monitoring Every shift SPS KLK3
3 Maintenance check 3 Visual check, replace or repair pipe Event base SPS HM
failure

Crack in pipe Tensile force overload Crack Leak Shutdown pump 1 Operator round 1 Do operator round, visual check for Every shift SPS OP
abnormalitiers in condensate pipe
2 Maintenance check 2 Visual check, replace or repair pipe Event base SPS HM
failure
Crack in molecular Crack Leak Shutdown pump 1 Operator round 1 Do operator round, visual check for Every shift SPS OP
structure (dislocation) abnormalitiers in condensate pipe

2 Maintenance check 2 Visual check, replace or repair pipe Event base SPS HM
failure
Pressure hammer Crack Leak Shutdown pump 1 Operator round 1 Do operator round, visual check for Every shift SPS OP
abnormalitiers in condensate pipe
2 Maintenance check 2 Visual check, replace or repair pipe Event base SPS HM
failure

Cracked weld Weld penetration Thin-edge tube Leak Shutdown pump 1 Operator round 1 Do operator round, visual check for Every shift SPS OP
abnormalitiers in condensate pipe
2 Maintenance check 2 Visual check, replace or repair pipe Event base SPS HM
failure
Vibration Crack Leak Shutdown pump 1 Operator round 1 Do operator round, visual check for Every shift SPS OP
abnormalitiers in condensate pipe
2 Maintenance check 2 Visual check, replace or repair pipe Event base SPS HM
failure

Name Position Date Siganture

Prepared by Danny Yunarta AMA ENG. Boiler & Aux.

Reviewed by Erik Pujianto SPS. Reliability

Approved by Hedwig Lunga S.P MENG